Cutting Plate Compression Mold for Deep Depressions and Uniform Compaction
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Solution Overview
Problem
Producing cutting plates with deep depressions and varying local aspect ratios is challenging due to differential compression and shrinkage during sintering, leading to distortion, cracks, and the need for grinding to achieve precise dimensions and structures like chip breakers.
Innovation Solution
A method using a heading tool with independently moveable main and form punches to apply uniform pressure, allowing for precise formation of cutting edges and depressions without grinding, by controlling the preliminary and final pressing steps to ensure homogeneous compaction and minimize distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional uniaxial or multiaxial compression tools are used to produce cutting plates with deep depressions and varying local aspect ratios, then the basic green body can be formed, but differential compression and shrinkage during sintering occur leading to distortion, cracks, and the need for grinding
Solution Approach 1:
The compression tool is segmented into multiple independent punches (first punch, second punch, third punch, fourth punch) that can move along different axes. Each punch can be independently controlled to apply pressure to specific regions of the powder mixture, allowing differential compression to be precisely managed across different areas of the green body, thereby preventing distortion and cracks during sintering while achieving deep depressions and varying local aspect ratios
Solution Approach 2:
The compression tool employs dynamically controllable punches with independent movement along different axes. The control system adjusts the position and pressure applied by each punch during compression based on the desired green body geometry, enabling precise control over compaction density distribution. This dynamic control allows the system to accommodate varying local aspect ratios and deep depressions without causing differential shrinkage issues during subsequent sintering
2Shape
If deep depressions are formed in the main surfaces to create cutting edges, then the desired cutting plate shape and structure are achieved, but the risk of cracks and pores increases during sintering
Solution Approach 1:
The compression process is performed as a preliminary action before sintering to create the green body with the desired depression geometry. By carefully controlling the compression force distribution during this preliminary shaping stage, the powder mixture is compacted into a stable green body structure that maintains its integrity during subsequent sintering. The independent punch system allows preliminary compaction that prevents void formation and ensures uniform density even in regions with deep depressions
Solution Approach 2:
Different regions of the green body are given different local qualities through selective compression. The independent punches apply varying pressures to different areas, creating regions with different compaction densities tailored to the local geometric requirements. This local quality control ensures that areas with deep depressions receive appropriate compaction to prevent cracking while maintaining the desired final shape
3Productivity
If conventional compression tools are used, then the process is simpler, but grinding is required to achieve precise dimensions and structures after sintering
Solution Approach 1:
The compression tool is designed to preliminarily form the green body with the exact final geometry including deep depressions, cutting edges, and varying local aspect ratios. By performing the shaping action during compression before sintering, the tool eliminates the need for subsequent grinding operations. The preliminary compression creates a stable green body structure that maintains its precise dimensions through the sintering process
Solution Approach 2:
The compression tool performs the shaping function that would otherwise require a separate grinding operation. By integrating the geometry creation directly into the compression forming stage, the system makes the compression process self-sufficient for producing the final precise dimensions, eliminating the need for additional machining steps and improving overall productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of cutting plates with high precision and desired shapes without grinding, reducing the risk of cracks and pores, and allowing for additional structures like chip breakers, while maintaining the desired dimensions and aspect ratios.
Implementation Method 1
at least one heading tool including at least one punch for compression of the powder mixture along a direction perpendicular to the (first) direction of movement of the side punches in order to form the main surface of the cutting plate
Implementation Method 2
The cutting plate, which is obtained after sintering the green body
Data Source
AI summary
A compression tool, a cutting plate and a method of producing a cutting plate by multiaxial pressing a powder mixture of a hard metal component and a binder to form a green body is provided. After pressing, the body has two parallel main surfaces and a peripheral edge surface extending between and connecting the main surfaces. The main surfaces include depressions, such that cutting edges are formed at the intersection of the bottom of the depressions and at least a part of the edge surface. A heading tool includes a main punch and an independently moveable form punch. In a first pressing step, the form punch is moved towards the powder mixture to form a preliminarily compressed portion. In a second step, the main punch and the form punch are both moved towards a final position to provide the green body with its final dimensions including the depressions